Cylinder Block Inspection

PROCEDURE

After disassembling the engine, clean and wash the cylinder block by immersing it in a tank with cleaning solution. Then flush it with a jet of the same solution under pressure to clean the oil passages. Blow out and dry the cylinder block with compressed air, especially the oil passage system. Inspect the block. If there are cracks in the crankshaft bearing bulkheads or other areas, replace the block. The cylinder bore surfaces must have no signs of wear, cracks, scratches, or corrosion. Minor scratches can be ground off; in other cases, the cylinders must be bored to a repair size.

Warning: All four cylinders must be bored to the repair size, even if wear, scoring, etc. is present in only one cylinder. After boring, hone the cylinder bores. Check the cooling jacket for leaks. To do this, plug all holes in the block except one, through which apply compressed air into the cooling jacket. Lower the block into a tank of water and apply compressed air. There must be no air leakage. Also check the oil galleries.

Check the piston-to-cylinder clearance (refer to subsection 2.2.1.12).

Measure the cylinder bore diameter (refer to subsection 2.2.1.12). Maximum permissible cylinder out-of-round is 0.04 mm. Permissible cylinder taper is 0.15 mm. Taper is calculated as the difference between the cylinder diameters at the bottom and at the top. If the taper is greater, bore the cylinders to the repair size. Check the flatness of the block surface on which the cylinder head is installed, using a straightedge and feeler gauge. The check is performed in the same way as for the cylinder head. Maximum permissible block distortion is 0.1 mm.